Mems device

ABSTRACT

A MEMS device includes a fixed electrode and a movable electrode arranged isolated and spaced from the fixed electrode by a distance. The movable electrode is suspended against the fixed electrode by one or more spacers including an insulating material, wherein the movable electrode is laterally affixed to the one or more spacers.

REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No.14/091,492 filed on Nov. 27, 2013, the contents of which areincorporated by reference in its entirety.

FIELD

Embodiments of the present disclosure refer to a MEMS device, a MEMSdevice used as an acceleration sensor, a humidity sensor, a bolometerand a pressure sensor as well as to a method for manufacturing a MEMSdevice.

BACKGROUND

A MEMS device, also referred to as microelectromechanical system, isoften used as sensor like acceleration sensors, pressure sensors oracoustic wave sensors (microphone). All of these MEMS devices have amovable element, for example a membrane or a cantilever, wherein themotion of the movable element, e.g. caused by a pressure change or anacceleration, may be detected capacitively. Thus, a common variant of aMEMS device comprises a movable electrode as a movable element and afixed electrode facing the movable electrode so that a distance changebetween the two electrodes (due to the motion of the movable element)may lead to a capacitive change.

Typically, MEMS devices have an impressed capacitance which is mainlydefined by the two electrodes and a parasitic capacitance of the MEMSdevice. The capacitance change indicative for the motion of the movableelement is often relatively small when compared to the entirecapacitance of the MEMS device. In order to compensate manufacturingrelated deviations, especially in connection with the parasiticcapacitance, means for offsetting are provided. Thus, there is the needfor an improved approach which enables to reduce the parasiticcapacitance.

SUMMARY

An embodiment of the disclosure provides a MEMS device comprising afixed electrode and a movable electrode. The movable electrode isarranged isolated and spaced from the fixed electrode by a distance. Themovable electrode is suspended against the fixed electrode by one ormore spacers comprising an insulating material, wherein the movableelectrode is laterally affixed to the one or more spacers.

A further embodiment provides a MEMS device comprising a substrate and amovable electrode. The substrate comprises a fixed electrode. Themovable electrode is arranged isolated and spaced from the fixedelectrode by a distance that has a square shape. The movable electrodeis suspended against the fixed electrode by one or more spacerscomprising an isolating oxide at its corners, wherein the movableelectrode is laterally fixed to the one or more spacers. The distancebetween the fixed electrode and the movable electrode is variable,wherein a variation of the distance leads to a variation of acapacitance.

According to a further embodiment, a MEMS device comprises a fixedelectrode and a movable electrode arranged isolated and spaced from thefixed electrode by a distance. The movable electrode is suspendedagainst the fixed electrode by one or more spacers comprising aninsulating material, wherein the movable electrode is laterally fixed tothe one or more spacers. Here, a footprint of the one or more spacers isat least twenty times smaller when compared to a footprint of themovable electrode.

A further embodiment provides a method for manufacturing a MEMS device.The method comprises providing a sacrificial layer to a fixed electrode,providing a movable electrode to the sacrificial layer such that a layerstack, comprising the sacrificial layer and the movable electrode, isformed. Furthermore, the method comprises providing one or more spacerscomprising an insulating material adjacent to the layer stack such thatthe movable electrode is laterally affixed to the one or more spacersand removing the sacrificial layer at least in a portion aligned with aportion of the movable electrode such that the movable electrode isspaced from the fixed electrode by a distance. As a result, the movableelectrode is suspended against the fixed electrode by the one or morespacers.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present disclosure will subsequently be discussedreferring to the enclosed drawings, wherein

FIG. 1 shows a schematic cross sectional view of a MEMS devicecomprising two electrodes which are suspended against each other via oneor more spacers according to a first embodiment;

FIGS. 2 a and 2 b show a cross sectional view and a top view of afurther MEMS device according to an embodiment;

FIGS. 3 a to 3 f show subsequent acts of a method for manufacturing theMEMS device of FIGS. 2 a and 2 b;

FIG. 4 a shows a top view of MEMS device used as an acceleration sensoraccording to an embodiment;

FIG. 4 b shows a top view of a MEMS device used as a pressure sensoraccording to an embodiment; and

FIGS. 5 a and 5 b show a cross sectional view and a top view of anotherMEMS device comprising two electrodes which are suspended against eachother via one or more spacers embedded in one of the electrodesaccording to another embodiment.

DETAILED DESCRIPTION

Different embodiments of the teachings disclosed herein willsubsequently be discussed referring to FIGS. 1 to 5, wherein in thedrawings identical reference numerals are provided to objects having anidentical or a similar function so that objects referred to by identicalreference numerals within different embodiments are interchangeable andthe description thereof is mutually applicable.

FIG. 1 shows a cross sectional view of a MEMS device 10 comprising afixed electrode 12 and a movable electrode 14. Here, the fixed electrode12 and the movable electrode 14 are arranged so that both are facingeach other having a distance 16 in between. In one embodiment the twoelectrodes 12 and 14 are substantially parallel to each other. The twoelectrodes 12 and 14 are spaced from each other by one or more spacers18. The one or more spacers are arranged between two electrodes 12 and14 and attached to same. In detail, the spacers 18 may be affixed to thefixed electrode 14 via a main surface 12 m which faces toward themovable electrode 14. Further, the spacers 18 are affixed to the movableelectrode 14 via an end face 14 f of the movable electrode 14; i.e. thatthe one or more spacers 18 are arranged laterally adjacent to themovable electrode 14 (and thus laterally adjacent to each other).Background of the lateral arrangement of the movable electrode 14 andthe spacers 18 will be discussed below after discussing the entirestructure and the functionality of the MEMS device 10.

The fixed electrode 14 is fixed, so same may, for example, be arrangedat a substrate (not shown). Vice versa, the movable electrode 14 ismovable at least along a first direction (illustrated by the arrow 16).In order to realize the motion, the movable electrode 14 forms or has adeformation area. The deformation area may alternatively be formed atthe connection or the borderline between the movable electrode 14 andthe spacer 18 or by the spacer 18 itself. In general, this means withrespect to the one or more spacers 18 that the purpose of the one ormore spacers 18 is to provide a suspension for the movable electrode 14against the fixed electrode 12.

The two electrodes 12 and 14 form a capacitance, so the two electrodes12 and 14 are isolated from each other. Therefore, these spacers 18comprise an insulating material like an oxide or a nitride.Alternatively, the spacer 18 may comprise a different insulatingmaterial, for example mono-silicon, wherein doping is selected such thatthe mono-silicon is insulating.

The motion dimension is arranged such that the distance 16 is variable.A variation of the distance 16 causes a variation of the capacitance.Consequently, a distance change or a motion of the movable electrode 14is detectable due to the capacitance change. Due to the lateralconnection between the movable electrode 14 and the spacers 18 via theend faces 14 f it can be avoided that large portions of the electrodes12 and 14 are facing each other with an oxide in between. Note thatthese areas typically cause parasitic capacitances. The backgroundthereof is that the parasitic capacitance is mainly caused in areas ofthe oxide or, in general terms, of the dielectric due to the increaseddielectric constant ε_(spacer) (e.g. for an oxide 3.9) when compared tothe dielectric constant ε_(cavity) of the cavity (for here 1.0, c.f.area marked by 16). Thus, the structure of the MEMS device 10 enablesreducing the areas mainly causing the parasitic capacitance. Expressedin other words, this embodiment has the advantage that the capacitanceis mainly defined by the overlap area of the two electrodes 12 and 14and the distance 16 between the two electrodes 12 and 14. Thus, incontrast to state of the art MEMS devices, the MEMS device 10 has areduced parasitic capacitance due to the way of suspending the movableelectrode 14. This leads to improved electrical characteristics. A maineffect is that the circuit for evaluating the motion of the movableelectrode 14 does not need means for offsetting the signal of the device10.

With respect to FIGS. 2 a and 2 b a further embodiment of a MEMS device10′ will be discussed. Here, the MEMS device 10′ is shown in a crosssectional view (AA) in FIG. 2 a, wherein FIG. 2 b shows a top view ofthe device 10′. The device 10′ comprises a substrate 20, on which thefixed electrode 12 is formed or, expressed more generally, whichcomprises the fixed electrode 12. The second electrode 14 is arrangedwith the distance 16 above the surface 12 m. According to thisembodiment, the movable electrode 14 is suspended by a plurality ofspacers 18 a, 18 b, 18 c and 18 d. Here, the electrode forms a membrane14 and has a deformation zone which lies adjacent to or at theborderline between the membrane 14 and the spacers 18 a, 18 b, 18 c and18 d. The plurality of spacers 18 a, 18 b, 18 c and 18 d are arranged atthe corners of the movable electrode 14 with openings in-between. Notethat the openings are marked by the reference numerals 19 a, 19 b, 19 cand 19 d. As shown by the embodiment of FIG. 2 b, the openings 19 a, 19b, 19 c and 19 d are arranged at the longitudinal sides of the squareshaped membrane 14.

As can be seen especially in the top view 2 b, an added footprint of theplurality of spacers 18 a, 18 b, 18 c and 18 d is significantly smallerwhen compared to the footprint of the movable electrode 14. For example,a proportion between the two footprints may be 1:10 or 1:20 or even1:100. Starting from an exemplary size of the movable electrode 14 of 35μm×35 μm (up to 200 μm×200 μm) a footprint of a respective spacer 18 a,18 b, 18 c or 18 d is smaller than 70 μm or smaller than 20 μm² (smallerthan 5% or 1% of the footprint of the movable electrode 14). Thefootprint size relates to the sum of all spacers 18 a, 18 b, 18 c and 18d. Thus, a respective footprint of a single spacer 18 a, 18 b, 18 c or18 d may be smaller than 2.5% or even smaller than 0.25% of a footprintof the movable electrode 14 (dependent on the number of spacers 18 a, 18b, 18 c and 18 d). This leads to the above discussed advantage of theimproved electric characteristic.

According to a further embodiment, a conductor 26 may be arranged at oneof the spacers 18 a, 18 b, 18 c or 18 d in order to electrically connectthe movable electrode 14. This conductor 26 is arranged as a layerformed along the surface of the spacer 18 a such that same extends fromthe substrate 20 onto the movable electrode 14. In order to isolate theconductor from the electrode 12, the substrate 20 may comprise anisolator 28 arranged between the conductor 26 and the electrode 12according to a further embodiment. According to this further embodiment,the conductor 26 may comprise a portion 26 a extending through theisolator 28 into the substrate 20.

With respect to FIGS. 3 a to 3 f an example method for manufacturing theMEMS device 10′ will be discussed.

FIG. 3 a shows a first act of providing the substrate 20 and the fixedelectrode 12 on the substrate 20. After that, a sacrificial layer 32 isdeposited on the surface 12 m of the fixed electrode 12, as shown byFIG. 3 b. In one embodiment, the sacrificial layer 32 may be depositedat the entire surface 12 m of the electrode 12, wherein the thickness ofthe sacrificial layer 32 is selected based on the distance 16 (cf. FIG.2 a). The material of the sacrificial layer 32 may be or may compriseSiGe or another material which may be etched by isotropic etching. UsingSiGe as the sacrificial layer 32 has the advantage that the movableelectrode 14, e.g. comprising monocrystalline silicon, may be formed byusing epitaxy. An etch rate of the sacrificial layer 32 is different(for example higher) when compared to an etch rate of the membrane 14 orof another functional layer (e.g. electrode 12, 14 and 32 or spacer 18)in order to enable selectively etching (wet or dry) of the sacrificiallayer 32.

FIG. 3 c shows the method after providing the movable electrode 14 onthe sacrificial layer 32. The movable electrode 14 may comprisepolysilicon, monosilicon or a metal like alloy, wherein the selectedmaterial typically depends on the material of the sacrificial layer 32and especially on the technology which is used for removing thesacrificial layer 32. In detail, polysilicon, monosilicon and nitride asthe material for the movable electrode 14 is typically used when theMEMS device is manufactured in the FEOL (Front End of Line), wherein amovable metal-electrode 14 is typically used when the MEMS device 10′ ismanufactured in the BEOL (Back End of Line). Note that monocrystallinesilicon enables fabricating a robust and reliable electrode 14 having alow stress gradient. Furthermore, the material of the movable electrode14 is selected dependent on the material of the spacers 18 (providedduring one of the next acts).

In detail, FIG. 3 c illustrates the act of structuring the movableelectrode 14. Here, the layer stack comprising the two layers 14 and 32is etched such that the shape, e.g. the square shape, of the movableelectrode 14 is defined. In other words, that means that the structureof the layer stack 14, 32 is defined by using lithography technologiesand/or anisotropic etching technologies. The result of this actillustrated by FIG. 3 c is a layer stack 14, 32 having the desired finalshape of the movable electrode 14.

The next act, illustrated by FIG. 3 d, is the providing of the spacers18. Here, the act is performed such that the spacers 18 are arrangedaround the layer stack 14, 32. Thus the spacers 18 are typicallyprovided laterally besides the movable electrode 14 or beside the layerstack 14, 32, e.g. by deposition of the spacer oxide. The deposition ofthe spacer 18 is performed such that the thickness of the spacers 18substantially complies with a thickness of the layer stack in order toenable the connection between the movable electrode 14 and the spacers18 and such that a good (adherent) connection between the movableelectrode 14 and the spacers 18 is achieved.

The spacers 18 may be provided in a structured manner, e.g. by using amask, such that the footprint is as low as possible in order to reducethe parasitic capacitance as explained above. The providing of thespacers 18 in a structured manner simultaneously enables one to providesame such that the openings (cf. FIGS. 19 a, 19 b, 19 c and 19 d) arearranged in between. These openings have the purpose to enable theremoving of the sacrificial layer within one of the next acts.Alternatively the shape of the spacers 18 and thus the footprint as wellas the openings of the spacers 18 may be limited afterwards by usinganother (for example anisotropic) etching process.

As illustrated by FIG. 3 e, the next act is to remove the sacrificiallayer 32. This act may be done by isotropic (wet or dry) etching. Due tothe openings between the spacers 18 a good accessibility is achieved.After removing the sacrificial layer 32, the movable electrode 14 issuspended by the laterally affixed spacers 18. It should be noted thatin one embodiment the sacrificial layer 32 is removed completely, butmay alternatively be removed mainly or a least partially, i.e. more than75%, 90% or even 99% with reference to the entire sacrificial layer area32.

FIG. 3 f shows a last, optional act of the manufacturing method, inwhich the movable electrode 14 is electrically contacted. Here, theelectrical connector 26 is provided on the surface of one of the spacers18 such that the conductor 26 extends from the substrate 20 to thesecond electrode 14.

It should be noted that the shown method for manufacturing mayoptionally comprise further acts like polishing or planarization.

FIG. 4 a shows a further MEMS device 10″ which is substantially equal orsimilar to the MEMS device 10′ of FIG. 2 a, wherein the movableelectrode 14″ is formed as a cantilever. The hammer-shaped cantilever14″ is suspended by two spacers, namely the spacers 18 a and 18 b.Regarding the further elements, namely the first electrode 12, thesubstrate 20, the conductor 26 and the isolator 28, the MEMS device 10″is equal or similar to the MEMS device 10′. The shown MEMS device 10″may be used as an acceleration sensor. According to a furtherembodiment, the acceleration sensor 10″ may comprise a lid arranged onthe substrate 20 such that the MEMS structure comprising the twoelectrodes 12 and 14″ (14) is shielded against the surrounding.

FIG. 4 b shows a further MEMS device 10′″. The further MEMS device 10′″is substantially equal or similar to the MEMS device 10′ of FIG. 2 a,wherein the openings 19 a, 19 b, 19 c and 19 d are closed by furtherspacers 36 a, 36 b, 36 c and 36 d. Due to the additional spacers 36 a,36 b, 36 c and 36 d the movable electrode 14 forms a closed membrane sothat a cavity between the two electrodes 12 and 14 is hermeticallyisolated. This enables the use of the MEMS device 10′″ for differentapplications. For example, the closed membrane 14 enables forming apressure sensor due to the fact that a pressure difference between apressure inside the closed cavity and an outside pressure leads to adeformation of the membrane 14 which can be capacitively measured, asexplained above.

From the manufacturing point of view, it should be noted that thespacers 36 a, 36 b, 36 c and 36 d are formed on the substrate 20 or onthe fixed electrode 14 after the sacrificial layer (cf. FIG. 3 e) hasbeen removed.

Although in the above discussed embodiments the spacers have beendiscussed in the context of a spacer arrangement according to which thespacers are arranged around the movable electrode 14, it should be notedthat the one or more spacers may also be arranged within the electrodearea 14. Such an arrangement will be discussed below.

FIGS. 5 a and 5 b show a further MEMS device 10″″, wherein the MEMSdevice 10″″ is illustrated by a cross section view (AA) in FIG. 5 a andby a top view in FIG. 5 b. The MEMS device 10″″ comprises the substrate20 comprising the fixed electrode 12″″ and the movable electrode 14″″which is arranged spaced by the distance 16 with reference to thesurface 12 m of the fixed electrode 12. As illustrated the movableelectrode 14″″ is suspended by a spacer 18″″ which lies within an areaof the movable electrode 14. That means that the spacer 18″″ extendsfrom the surface 12 m through the movable electrode 14″″ such that thespacer 18″″ is embedded into the movable electrode 14″″.

Alternatively, the shown MEMS device 10″″ may also comprise a pluralityof spacers 18″″ embedded into the movable electrode 14″″. According to afurther embodiment the conductor for electrically connecting the movableelectrode 14″″ may be arranged within the spacers 18″″ (not shown).

The manufacturing of the MEMS device 10″″ is substantially similar tothe manufacturing of the above discussed MEMS devices. Here, a hole forthe spacer 18″″ (through which the spacer 18″″ should extend) isprovided into the movable electrode 14″″ and the sacrificial layer 32during the act of defining the shape of the movable electrode 14″″ (cf.FIG. 3 c). Integrating of the one or more holes into the movableelectrode 14″″ for the one or more spacers 18″″ may be based onlithography technologies and/or anisotropic etching.

With respect to FIGS. 2 a, 2 b and to FIG. 4 a it should be noted thatthe shown MEMS 10′ and 10″ may be used as a humidity sensor. Here, aliquid film which is accumulated on the membrane 14 changes, for exampleproportionally, the capacitance of the MEMS device 10′ or 10″ so that adetectable capacitance is indicative for the respective humidity. Thiscapacitance change caused by the liquid film is quite small, so that theabove described principle that enables one to avoid or to reduceparasitic capacitance is advantageous.

According to further embodiments, the MEMS device 10′ forms a bolometer.Here, it is advantageous that the material of the spacers 18 a, 18 b, 18c and/or 18 d may be selected dependent on a desired, e.g. a reduced,thermal conductivity.

Although the membrane 14 has been discussed in context of a membranehaving a square shape, it should be noted that the shape of the membrane14 may be different, for example round.

Referring to FIGS. 5 a and 5 b it should be noted that a MEMS deviceaccording to a further embodiment may comprise spacers 18″″ embeddedinto the movable electrode 14″″ as well as spacers 18 a, 18 b, 18 c and18 d surrounding the electrode 14″″, as shown by FIGS. 2 a and 2 b.

In general, the above described embodiments are merely illustrative forthe principle of the present disclosure. It is understood thatmodifications and variations of the arrangements and the detailsdescribed herein will be apparent to others skilled in the art. It isthe intent therefore to be limited only by the scope of the appendedpatent claims and not by the specific details presented by way ofdescription and explanation of the embodiments herein.

1. A MEMS device, comprising: a fixed electrode; and a movable electrodearranged isolated and spaced from the fixed electrode by a distance;wherein the movable electrode is suspended against the fixed electrodeby one or more spacers comprising an insulating material, wherein themovable electrode is laterally affixed to the one or more spacers. 2.The MEMS device according to claim 1, wherein the fixed electrode isformed by or attached to a substrate.
 3. The MEMS device according toclaim 1, wherein the movable electrode has a square shape and whereinthe movable electrode is suspended at one or more corners of the movableelectrode via the one or more spacers, respectively.
 4. The MEMS deviceaccording to claim 1, wherein the one or more spacers are embedded inthe movable electrode.
 5. The MEMS device according to claim 1, whereinthe one or more spacers comprise an oxide or nitride.
 6. The MEMS deviceaccording to claim 1, wherein the one or more spacers have a differentmaterial or a different grid structure when compared to a material or agrid structure of the movable electrode.
 7. The MEMS device according toclaim 1, wherein a footprint of the one or more spacers is at least 10times smaller when compared to a footprint of the movable electrode. 8.The MEMS device according to claim 1, wherein the distance between thefixed electrode and the movable electrode is variable and wherein avariation of the distance leads to a variation of a capacitance.
 9. TheMEMS device according to claim 1, wherein the movable electrode iselectrically contacted via a conductor arranged at one of the one ormore spacers.
 10. The MEMS device according to claim 1, wherein the oneor more spacers are separated from each other by an opening extendingalong the movable electrode.
 11. The MEMS device according to claim 1,wherein the movable electrode is formed as a cantilever.
 12. The MEMSdevice according to claim 11, wherein the MEMS device forms anacceleration sensor or a humidity sensor.
 13. The MEMS device accordingto claim 2, wherein the one or more spacers have a material having areduced thermal conductivity when compared to a material of the movableelectrode or of the substrate.
 14. The MEMS device according to claim13, wherein the MEMS device forms a bolometer.
 15. The MEMS deviceaccording to claim 10, wherein a further spacer is arranged in an areaof the opening in order to hermetically close a cavity below a membraneformed by the movable electrode.
 16. The MEMS device according to claim15, wherein the MEMS device forms a pressure sensor.
 17. A MEMS device,comprising: a substrate comprising a fixed electrode; and a movableelectrode arranged isolated and spaced from the fixed electrode by adistance, the movable electrode having a square shape; wherein themovable electrode is suspended from the fixed electrode by one or morespacers comprising an insulating oxide at its corners, wherein themovable electrode is laterally affixed to the one or more spacers;wherein the distance between the fixed electrode and the movableelectrode is variable and wherein a variation of the distance leads to avariation of a capacitance.
 18. A MEMS device, comprising: a fixedelectrode; and a movable electrode arranged isolated and spaced from thefixed electrode by a distance; wherein the movable electrode issuspended from the fixed electrode by one or more spacers comprising aninsulating material, wherein the movable electrode is laterally affixedto the one or more spacers, wherein a footprint of the one or morespacers is at least 20 times smaller than a footprint of the movableelectrode.
 19. A method for manufacturing a MEMS device, comprising:providing a sacrificial layer over a fixed electrode; providing amovable electrode over the sacrificial layer such that a layer stackcomprising the sacrificial layer and the movable electrode is formed;providing one or more spacers comprising an insulating material adjacentto the layer stack such that the movable electrode is laterally affixedto the one or more spacers; and removing the sacrificial layer at leastin a portion aligned with a portion of the movable electrode such thatthe movable electrode is spaced from the fixed electrode by a distancethat is related to a thickness of the sacrificial layer; wherein themovable electrode is suspended from the fixed electrode by the one ormore spacers.
 20. The method according to claim 19, wherein providingthe one or more spacers is performed such that an opening is formed inbetween.
 21. The method according to claim 19, wherein providing the oneor more spacers comprises anisotropic etching and/or using lithographyin order to limit a footprint of the one or more spacers.
 22. The methodaccording to claim 21, wherein the anisotropic etching and/or usinglithography is performed such that the footprint of the one or morespacers is at least 10 times smaller than a footprint of the movableelectrode.
 23. The method according to claim 20, wherein removing thesacrificial layer comprises etching or isotropic etching through theopening.
 24. The method according to claim 20, further comprisingclosing the opening by a further spacer after removing the sacrificiallayer.
 25. The method according to claim 19, further comprising definingthe area of the layer stack by using lithography and/or anisotropicetching before providing the one or more spacers.
 26. The methodaccording to claim 25, wherein defining the area of the layer stackcomprises forming at least one hole in the layer stack for the one ormore spacers, and wherein the one or more spacers are embedded in themovable electrode.
 27. The method according to claim 19, whereinremoving the sacrificial layer is performed in a portion where the fixedelectrode is aligned with the entire movable electrode.
 28. The methodaccording to claim 19, wherein an etch rate of the sacrificial layerdiffers from an etch rate of the membrane and/or of the spacer.